Laminated materials



y 29, 1956 w. T. MULLEN 2,748,043

LAMINATED MATERIALS Filed July 7, 1955 SHEET LEAD ALLOY ASPHALT THIN SHEET COPPER ASPHALT SHEE LEAD ALLOY ASPHALT IMPREGNATED AND CREPED PAPER ASPHALT WITH GLASS FIBER FILLER PAPER ASPHALT sum-:1 LEAD ALLOY F l G 2 ASPHALT THIN SHEET COPPER ASPHALT SHEET LEAD ALLOY ASPHALT PAPER ASPHALT WITH GLASS FIBER FILLER ASPHALT IMPREGNATED AND CREPED PAPER INVENTOR.

WILLIAM T. MULLEN ATTO R N EY.

United States Paten f LAMIENATED MATERIALS William T. Mullen, Philadelphia, Pa. Application July 7, 1953, Serial No. 366,520

2 Claims. (Cl. 154-51) This invention relates to laminated materials and more particularly to sheet material which is particularly useful in the field of building construction.

It has heretofore been the practice in the field of building construction to employ sheet copper for flashing, roofing covering and the like, of desired thickness, the preferred weights for flashing being identified as ounce or 16 ounce copper i. e. sheet copper, weighing 10 or 16 ounces to the square foot. While copper is a desirable material for these purposes, because of its resistance to oxidation, it has objectionable characteristics in that with expansion and contraction it tends to lose its ductility and become brittle. Copper in sheet form, and particularly if exposed, is susceptible to attack by acids present in certain building materials, and specifically in cinder blocks. The smooth surfaces of the copper, also, are not suited for the bonding thereto of cement, mortar and the like.

The supply of copper is also rather limited at timesand at such times increased building activity of housing projects and the like may also be desired and required.

In my prior application filed May 29, 1951, Serial No. 228,948, now Patent No. 2,695,854, there is shown a laminated material which is particularly suitable for certain types of building construction but which by reason of the exposed copper face has an exterior surface which is subject to acid attack and corrosion, may be injured by careless handling and use, will not readily bond to the masonry in which it is used, and may cause discoloration of light stone and brickwork in the same manner as occurs with conventional sheet copper fiashings.

It is the principal object of the present invention to provide sheet material made from a plurality of components in laminated form which is suitable foruse in places where sheet copper has heretofore been employed and which has advantageous features not possessed by sheet copper of the type heretofore employed for flashings.

It is a further object of the present invention to provide sheet material made from a plurality of components in laminated form which is suitable for use in places where sheet lead, except for its cost, lack of alkali resistance, lack of strength, and lack of ability to retain its shape, might have been used, and which has advantageous features not possessed by sheet lead.

It is a further object of the present invention to provide a sheet material, made from a plurality of components in laminated form, which is suitable for use for flashings in building construction, for damp proofing, for membrane water proofing, for roofing covering, for shower pans, and for other purposes.

It is a further object of the present invention to provide sheet material, made from a plurality of components in laminated form, which is strong, light in weight, with a good body, permanent, waterproof, resistant to oxidation and corrosion, ductile, easily handled and capable of being bent to the required shape, retentive of its shape when bent, free from any tendency to cause discoloration of '2 4 the masonry in which it is used, and which has numerous other advantages.

It is a further object of the present invention to provide sheet material of the character aforesaid which requires a minimum of scarce or diflicult to obtain components.

It is a further object of the present invention to provide sheet material of the character in which the exterior or exposed faces are abrasive resistant.

it is a further object of the present invention to providesheet material of the character aforesaid in which the metallic components are protected against corrosion or erosion.

It is a further object of the present invention to provide sheet material of the character aforesaid which may havethe two exposed faces of a character to permit it to bebonded to and securely held within the masonry con-- struction in which the material is used.

Other objects and advantageous features of the invention will be apparent from the specification and claims.

The nature and characteristic features of the invention will be more readily understood from the following description, taken in connection with the accompanying tion and drawing herein are illustrative merely, and that various modifications and changes may be made in the structure disclosed without departing from the spirit of the invention.

Referring more particularly to the drawing, the sheet material in accordance with the present invention, as there illustrated, comprises a plurality of laminations of specific components, hereinafter more fully described, in adherent engagement so as to prevent any slipping therebetween.

The sheet material includes as aconstituent part thereof, a metallic lamina 10 preferably consisting of a continuous lead alloy foil or sheet of a thickness in the range from 0.0010 to 0.007 inch. While any preferred lead alloy may be employed, an alloy consisting of about 99.8% of lead with antimony added to increase the stiffness has been found satisfactory.

On the inner face of thelamina 10, a coating 11 of asphalt is provided, in adherent engagement therewith, the coating being of a thickness resulting from the application of about 27 pounds of asphalt per 1000 square feet of suiface.

The face of the coating 11 opposite to the lamina it? has, in adherent engagement therewith, a continuous lamina 12 of electrolytic sheet copper of a thickness preferably in the range from 0.0010 to 0.007 inch. The lamina 12 has, in adherent engagement therewith, a coating 13 of asphalt, of the same or substantially the same characteristics as the coating 11.

The coating 11 has, in adherent engagement with the face thereof opposite to the lamina 12, a metallic lamina 14 preferably consisting of a lead alloy foil or sheet similar to the lamina 10. While the relative thicknesses of the lamina 10, 12 and 14 may be varied, they are preferably of substantially equal thickness and are preferably in the range of a total metal thickness from 0.003 to 0.021 inch.

While the lamina as thus described may be used without any exterior coating, as illustrated in Fig. 1, it is preferred for some uses, and as illustrated in Fig. 2 to V PatentedMaY 2?,

gamma 3 proiiid'e one or more enter protective coverings or layers.

Gne suitable cover may be in the form of asphalt coatings 15 preferably of the same, or substantially the same, thickness as the coating 11 and 13. Such coatings 15 provide a protective exterior covering and prevent injury to the foil laminae and 14 in use, particularly Where the masonry Components are rough cinder blocks, stone and the like which might abrad'e or puncture the laminae 10 or 14 if the same were not protected.

It is preferred additionally to provide on the exteriors of the coatings 15 and in adherent engagement therewith, further protective layers 16, one suitable material being paper laminae and while any strong paper may be ernployed, it is preferred to use kr'aft paper, such paper weighing about '45 pounds per ream having been found satisfactory. I

On the exterior of the layers 16 and in adherent engagement therewith, asphalt coatings 17 may be provided of a thickness the same, or substantially the same thickness as the coatings 11 and 13.

The coatings 17 may have embedded therein, a glass fiber reinforcement for added strength, reduction of tendency to tear or rupture and freedom from wicking efiect with respect to moisture. For this purpose a woven scrim of four glass fiber strands per inch in each direction, with a warp tensile strength of 32 pounds per inch of width and a weft or filling strength of 26 pounds per inch of width has been found satisfactory.

The coatings 17 preferably each have, in adherent engagement therewith, and as an outer or weather layer 18, a lamina of paper and for this purpose it is preferred to use an asphalt impregnated machine creped kraft paper,

such paper weighing about 45 pounds per ream having been found suitable, with an asphalt impregnated coating of the order of 30 to pounds per 1000 square feet.

The respective laminae are brought together in any desired manner and in adherent engagement as heretofore pointed out. The sheet material thus provided has been found suitable and acceptable for many of the uses for which either 10 ounce or 16 ounce copper sheets have heretofore been employed, requires only a small fraction of the total copper required for such copper sheets and weighs considerably less, thus reducing the cost of transportation and increasing the ease of handling, and is lower in cost.

The sheet material as thus provided seems to have an increased ductility and reduced brittleness in the metallic lamina 12, can be readily cut, bent, shaped and formed and when formed retains'its shape. It is also permanent, waterproof and vaporproof, resistant to oxidation and corrosion both from the acids found in building constructions of cinder blocks and to alkaline action which occurs, for example, with the laitance of Portland cement. At the same time the metallic components may be adequately protected against surface abrasion or rupture which might occur at the time the flashing is applied in the masonry construction, particularly when rough cinder blocks are employed. The laminated material also has a good body, is stronger and lower in manufacturing cost than comparable sheet copper or sheet lead, can be nailed and holds better than sheet metal and the overlapping joints at the edges or ends of the sheets in use may be readily sealed with asphalt. The relatively rough exterior surface of the form shown in Fig. 2 is such as to permit the bonding of masonry materials such as cement therewith, and the corrugations attendant upon the creping, which all extend in one direction, tend to channel out of the wall any condensation that might accumulate.

I claim: p

1. Sheet material comprising a first lamina of asphalt impregnated paper, a first asphaltic coating adherent to said first lamina, a second lamina of paper adherent to said first coating, a second asphaltic coating adherent to second paper lamina, a third lamina of lead foil adherent to said second coating, a third asphaltic coating adherent to said third lamina, a fourth lamina of electrolytic sheet copper adherent to said third asphaltic coating, a fourth asphaltic coating adherent to said fourth lamina, a fifth lamina of lead foil adherent to said fourth coating, a fifth asphaltic coating adherent to said fifth lamina, a Sixth lamina of paper adherent to said fifth coating, a sixth asphaltic coating adherent to said sixth lamina, and a seventh lamina of asphalt impregnated paper adherent to said sixth coating, said sheet material being readily bendable and retaining the shape to which it is bent.

2. Sheet material comprising a first lamina of asphalt impregnated and creped kraft paper, a first asphaltic coating adherent to said first lamina and having glass fibers incorporated therein, a second lamina of paper adherent to said first coating, a second asphaltic coating adherent to second paper lamina, a third lamina of lead foil adherent to said second coating, a third asphaltic coating adherent to said third lamina, a fourth lamina of electrolytic sheet copper adherent to said third asphaltic coating,

a fourth asphaltic coating adherent to said fourth lamina, a fifth lamina of lead foil adherent to said fourth coating, a-fifth asphaltic coating adherent to said fifth lamina, a sixth lamina of paper adherent to said fifth coating, a

, sixth asphaltic coating adherent to said'sixth lamina, and

a seventh lamina of asphalt impregnated and creped kraft paper adherent to said sixth coating, said sheet material being readily bendable and retaining the shape to which it is bent.

References Cited in the file of this patent UNITED STATES PATENTS 

1. SHEET MATERIAL COMPRISING A FIRST LAMINA OF ASPHALT IMPREGNATED PAPER, A FIRST ASPHALTIC COATING ADHERENT TO SAID FIRST LAMINA, A SECOND LAMINA OF PAPER ADHERENT TO SAID FIRST COATING, A SECOND ASPHALTIC COATING ADHERENT TO SECOND PAPER LAMINA, A THIRD LAMINA OF LEAD FOIL ADHERENT TO SAID SECOND COATING, A THIRD ASPHALTIC COATING ADHERENT TO SAID THIRD LAMINA, A FOURTH LAMINA OF ELECTROLYTIC SHEET COPPER ADHERENT TO SAID THIRD ASPHALTIC COATING, A FOURTH ASPHALTIC COATING ADHERENT TO SAID FOURTH LAMINA, A FIFTH 